4-Cylinder diesel engine (Engine 1.9 l)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine characteristics
  1
• Cylinders, engine block, support, cover
  2
• 1 Engine - remove and install
  2
• 1.1 Removal - instructions
  4
• 1.2 Engine - fix on the assembly support
  7
• 1.3 Notes on installation
  7
• 1.4 Tightening torque
  8
• 1.5 Subframe
  9
• 1.6 Additional indications related to installation
  10
• Crankshaft, pistons
  11
• 1 Engine - disassemble and assemble
  11
• 1.1 Poly-V belt - remove and install
  14
• 1.2 Semi-automatic tensioner pulley of the toothed belt - check
  15
• 2 Crankshaft and engine flywheel seal - remove and install
  16
• 2.1 Crankshaft sealant (pulley side) - replace
  17
• 2.2 Front flange of the crankshaft (pulley side) - remove and install
  20
• 3 Crankshaft - remove and install
  24
• 3.1 Crankshaft measurements
  25
• 4 Piston and rods - disassemble and assemble
  26
• 4.1 Measurements of pistons and cylinders
  30
• Cylinder head, Valve gear
  31
• 1 Cylinder head - assembly overview
  31
• 1.1 Tooth belt - remove, install, and adjust
  33
• 1.2 Cylinder head - remove and install
  37
• 1.3 Compression - check
  42
• 2 Valve mechanism - repair
  45
• 2.1 Valve seats - grind
  47
• 2.2 Valve guides - check
  49
• 2.3 Valve stem seals - replace
  49
• 2.4 Camshaft - remove and install
  51
• 2.5 Hydraulic tappets - check
  54
• Lubrication system
  56
• 1 Lubrication system components - remove and install
  56
• 1.1 Oil sump - remove and install
  59
• 1.2 Oil pump - remove and install
  61
• 1.3 Oil pressure switch F1 - check
  62
• Cooling system
  64
• 1 Cooling system components - remove and install
  64
• 1.1 Cooling system components on the body side
  64
• 1.2 Cooling system components on the engine side
  66
• 1.3 Connection diagram of the coolant hoses
  67
• 1.4 Coolant - drain and fill
  68
• 1.5 Radiator - remove and install
  71
• 1.6 Water pump - remove and install
  72
• 1.7 Thermostatic valve - remove and install
  74
• Fuel supply system
  77
• 1 Fuel supply system components - remove and install
  77
• 1.1 Fuel tank with accessories - remove and install
  77
• 1.2 Fuel filter - repair
  80
• 1.3 Safety measures for work on the fuel supply
  81
• 1.4 Rules for cleanliness
  81
• 1.5 Fuel tank - remove and install
  82
• 1.6 Pre-fuel supply pump - remove and install
  84
• 1.7 Fuel level measurer - remove and install
  86
• 1.8 Throttle control system - repair
  86
• Supply system - fuel injection (diesel)
  88
• 1 Diesel direct injection system - repair
  88
• 1.1 Safety measures
  88
• 1.2 Injection pump - repair
  88
• 1.3 Intake manifold - remove and install
  91
• 1.4 Injection pump - remove and install
  92
• 1.5 Injectors - remove and install
  96
• 1.6 Injectors - check
  97
• 2 Diesel direct injection system control unit J248
  99
• 2.1 Diesel direct injection system control unit J248 - remove and install
  99
• 2.3 Functions and components - adjust
  101
• Exhaust system
  102
• 1 Exhaust system components - remove and install
  102
• 2 Exhaust gas recirculation system components - remove and install
  104
• 2.1 Vacuum hose connection diagram
  105
• 2.2 Exhaust gas recirculation valve N18 - check
  105
• Chamber pre-heating system
  107
• 1 Chamber pre-heating system - check
  107
• 1.1 Pre-heating spark plugs - check
  107